The outlet from the turbo is 70mm (2.75in) downpipe, so it made sense to match that. So I measured up and worked out what I needed. The plan was to reuse the existing silencer (which is big and heavy but nice and quiet) which is 2inch input. So I bought a couple of 45degree 70mm bends. Once these arrived I realised that in my calculations I hadn't accounted for the length of the bend and there wasn't sufficient space before the silencer. So, order new silencer from Jetex which is a bit shorter, and slightly larger bore (2.5inch, you can't get them in 2.75in), and a 45deg bend in 2.5in for the tailpipe.
To get the 70mm down to the silencer I cut 2 8inch long wedges from the bend and then closed that up with a couple of exhaust clamps and then welded it together. I am not much good at welding, but by putting an aluminium tube under the weld means that burning through isn't a problem and the backing reduces the need for purging the weld from behind (something I don't have the luxury of).
After loads of cutting, welding, measuring, grinding etc I ended up with this.
I need to clean up the weld in the middle of the downpipe and weld the downpipe to the flange.
Finally I bolted it all up, welded up a support bracket with a captive nut, and modified the tailpipe to allow it to exit from the side of the body (its great being able to weld, even if I am rubbish at it).
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